REDUCED ENERGY CONSUMPTION IN PLASTICS … sole responsibility for the content of this report lies...

REDUCED ENERGY CONSUMPTION IN PLASTICS ENGINEERING

REVIEW OF ENERGY MANAGEMENT PRACTICES, BEST PRACTICE &

TRENDS WITHIN THE PLASTICS PROCESSING INDUSTRY ACROSS THE

WORLD

‘An overview of available energy best practice guidelines, case studies, technologies and organisations, from

across the world, relating to the plastics processing industry’

30th September 2005

The sole responsibility for the content of this report lies with the authors. It does not

represent the opinion of the Community. The European Commission is not responsible for

any use that may be made of the information contained therein.

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TABLE OF CONTENTS

EXECUTIVE SUMMARY .......................................................................................................................................... 3

BACKGROUND........................................................................................................................................................ 4

Introduction........................................................................................................................................................... 4

Potential Impacts .................................................................................................................................................. 4

RECIPE Partners.................................................................................................................................................. 4

Why RECIPE?...................................................................................................................................................... 5

RECIPE Activities ................................................................................................................................................. 5

Intelligent Energy - Europe ................................................................................................................................... 6

ASIA ......................................................................................................................................................................... 7

Overview .............................................................................................................................................................. 7

Available Guidelines ............................................................................................................................................. 7

Organisations ....................................................................................................................................................... 7

CANADA................................................................................................................................................................... 9

Overview .............................................................................................................................................................. 9

Available Guidelines ............................................................................................................................................. 9

Organisations ....................................................................................................................................................... 9

DENMARK.............................................................................................................................................................. 11

Overview ............................................................................................................................................................ 11

Available Guidelines ........................................................................................................................................... 11

Organisations ..................................................................................................................................................... 11

GERMANY ............................................................................................................................................................. 12

Overview ............................................................................................................................................................ 12


References ......................................................................................................................................................... 12

Articles relating to energy saving in plastic processing – Kunststoffe Magazine ................................................. 13

Articles relating to energy saving in plastic processing – FIZ Technik ................................................................ 14

NEW ZEALAND...................................................................................................................................................... 16

Overview ............................................................................................................................................................ 16


Organisations ..................................................................................................................................................... 16

SPAIN..................................................................................................................................................................... 18

Overview ............................................................................................................................................................ 18


Organisations ..................................................................................................................................................... 18

UNITED KINGDOM ................................................................................................................................................ 19

Overview ............................................................................................................................................................ 19


Organisations ..................................................................................................................................................... 21

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UNITED STATES ................................................................................................................................................... 23

Overview ............................................................................................................................................................ 23


Organisations ..................................................................................................................................................... 24

ADDITIONAL INFORMATION ................................................................................................................................ 25

ARGENTINA ...................................................................................................................................................... 25

AUSTRALIA ....................................................................................................................................................... 25

BELGIUM ........................................................................................................................................................... 25

BRAZIL............................................................................................................................................................... 25

CHILE................................................................................................................................................................. 25

FRANCE............................................................................................................................................................. 25

ITALY ................................................................................................................................................................. 26

SOUTH AFRICA................................................................................................................................................. 26

CONCLUSIONS ..................................................................................................................................................... 27

Countries Surveyed ............................................................................................................................................ 27

Guidelines Available ........................................................................................................................................... 27

Next Steps.......................................................................................................................................................... 27

APPENDIX 1........................................................................................................................................................... 29

Countries Surveyed ............................................................................................................................................ 29

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EXECUTIVE SUMMARY

RECIPE (Reduced Energy Consumption in Plastics Engineering) is a European funded project to provide plastics

processors with the knowledge, justification and tools needed to reduce energy consumption through the

implementation of best practice and the introduction of new technologies.

The RECIPE consortium conducted a survey of information related to best practice guidance and energy efficiency

in the plastics processing industry. This report aims to draw together the national guidelines available to establish

what constitutes best practice for the industry. Information has been compiled from European and non-European

countries.

In total, forty-two documents were sourced and they can be divided in to the following categories;

• 40% are best practice guidelines specifically aimed at the plastics industry.

• 7% are case studies illustrating examples of best practice in the plastics industry.

• 5% are case studies illustrating examples of best practice within the manufacturing sector.

• 31% are best practice guidelines relating to energy efficiency in any industry.

• 10% are national energy strategies.

• 7% are technical guides for the plastic industry.

The survey was carried out between March and September 2005 and includes: -

• An overview of the energy management practices within each country mentioned in the report.

• Organisations within each country that supply guidance relating to energy efficiency.

• A review of each of the documents available.

• Details of where to access the documents reviewed.

• Other sources of information.

• Countries surveyed include, Spain, Germany, Canada, United States, United Kingdom, Denmark and New

Zealand.

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BACKGROUND

Introduction

RECIPE (Reduced Energy Consumption in Plastics Engineering) is a European Union funded project to provide

plastics processors with the knowledge, justification and tools needed to reduce energy consumption through the

implementation of best practice and the introduction of new technologies. This industry comprises more than

27,000 companies (more than 80% SMEs) employing more than one million people, and with total sales of over

100 billion euros.

Potential Impacts

In 2001, 35.6 million tonnes of plastic were consumed in the EU, rising to approximately 40 million tonnes when the

key Eastern European processing countries are included. Based on UK industry figures for energy usage in each

of the major processing technologies (extrusion, blown film, injection moulding and blow moulding) and share of the

total processing capacity, we can estimate an average energy use of 1.85 kWh/kg for plastics processing. With a

consumption figure of 40 million tonnes, the total figure for energy usage is 74 x 109 kWh. This equates to a total

annual emission of more than 30 million tonnes of CO2.

If it were possible to reduce energy consumption across the industry by 10%, this would result in an annual

reduction in CO2 emissions of more than 3 million tonnes.

RECIPE Partners

RECIPE has 8 partner organisations from 6 countries.

• Rapra Technology Ltd (UK)

Europe’s leading independent plastics and rubber research and technology organisation providing

specialist technical, commercial and information services for the polymer industry and end-user industries

including the automotive, construction, electrical, medical, offshore, packaging and polyurethane sectors.

• British Plastics Federation (UK)

The BPF is the leading trade association for the UK plastics industry (representing approximately 80% of

turnover), a springboard for industry action, existing to exploit common opportunities and resolve shared

problems. Membership encompasses producers, suppliers and processors in addition to additive and

machinery suppliers and manufacturers.

• Danish Technology Institute (Denmark)

The Danish Technology Institute is a not for profit organisation that promotes growth by improving

interaction and encouraging synergy between research organisations, businesses and the community.

• ASCAMM+ (Spain)

ASCAMM+ is a not for profit organisation founded in 1979. It currently has over 200 members comprising

of a workforce of over 4000 people. ASCAMM+’s activities include specialised training, promotion of the

industry and advisory services.

• AIMPLAS (Spain)

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AIMPLAS is an innovation and technology centre based in Spain. Founded in 1990, AIMPLAS conducts

research within the plastics transformation sector in order to increase the competitiveness of the plastics

industry and related sectors.

• Pôle Européen de Plasturgie (France)

Pôle Européen de Plasturgie was founded in 1990 with the assistance of the plastics industry:

transformers, mould and die manufacturers, machine manufacturers, plastic producers and toolmakers. It

aims to increases the competitiveness of the industry by improving the research and technology

developments, from design to finished product.

• CRIF – Wallonie (Belgium)

CRIF-Wallonie started life in 1969 as CRIF Plastics; in order to answer the specific needs of the plastic

processing members of Agoria. The main activities can be split into three areas; engineering of materials

including the design of high tech components in plastic and metal, smart manufacturing and process and

rapid manufacturing.

• Fraunhofer Institut fuer Chemische Technologie ICT (Germany)

The research and design expertise of the Fraunhofer Institute for Chemical Technology ICT is primarily

geared towards products and processes in the fields of polymer engineering, environmental engineering,

electrochemistry and energetic materials.

Why RECIPE?

The foundations of RECIPE were developed from the recommendations of the Technology Roadmap (TRM) for

Low Energy Polymer Processing conducted by the Faraday Plastics Partnership, (a UK organisation with the aim of

improving the competitiveness of the UK plastics industry through research, development, transfer and exploitation

of new and improved science and technology). Technology Road Mapping is a high level tool for supporting

technology management and planning which has been widely adopted in industry to support national and sector

‘foresight’ initiatives. In its most basic form, a TRM can be considered as a time-based chart consisting of a

number of layers that can typically include commercial, technological, legislative and environmental perspectives.

The recommendations of the TRM aim to catalyse the plastics industry into measuring its energy use performance

and change for the better. This includes industry benchmarking and sectoral targets – a programme of market

research to study how energy efficient the polymer processing sector is in its current practices; a demonstration

unit – establishing a ‘show and tell unit’ to illustrate the benefits of energy efficiency, a cost of ownership model –

establishing a financial model for typical paybacks to incentivise the industry to adopt energy saving measures and

training – in energy measurement and management.

RECIPE Activities

The four key activities are:

• European Best Practice Guide

An industry specific guide providing advice related to the processes and working practices prevalent in the

industry.

• Publications

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RECIPE will issue a series of fact sheets relating to energy saving technologies, initiatives and practices

and a regular newsletter.

• Interactive Energy Efficiency Tools

The interactive toolkit will enable companies to evaluate energy consumption and look closely at individual

processes within the plant. It will then provide guidance on efficiency and highlight key plant areas where

they most substantial energy and cost savings can be made most easily. The Cosy of Ownership model,

included in the toolkit, will enable processors to calculate the cost of purchasing and operating a piece of

equipment over its projected lifetime, based on energy efficiency and projected usage.

• Information

Seminars will be run across Europe demonstrating the latest developments in technology, local energy

schemes, funding opportunities and the interactive tools developed by RECIPE.

RECIPE has also conducted a survey of plastics processors across Europe in order to establish where variations

exist from ‘typical’ usage and understand how companies view and manage their energy. This is available for

download from www.eurecipe.com.

Intelligent Energy - Europe

Intelligent Energy – Europe (EIE) is a European Community programme promoting energy efficiency and

renewable sources. The programme aims to encourage the development, demonstration and take-up of energy

efficient products, services and renewable energy sources.

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ASIA

Overview

There are very few guidelines readily available in Asia, however, in some areas energy efficiency and conservation

is becoming an important issue. The Energy Resources Section, Environment and Sustainable Development

Division of Economic and Social Commission for the Asia and Pacific (ESCAP), concluded that energy

benchmarking should be used in all energy intensive enterprises on the basis of best practice and a system of

energy auditing should be established in order to identify current patterns of energy usage and to point out areas of

potential savings.

Available Guidelines

• Eco Efficiency for Chemicals and Plastics Industry, (Asia Pacific Economic Co-operation, 1997)

A guide introducing eco-efficiency practices for the plastics and chemical industries. It is aimed at SME’s

and provides practical guidance for identifying and evaluating opportunities for eco-efficiency in the

workplace.

http://www.apec.org/apec/publications/all_publications/small___medium_enterprises.html

• Indian Petrochemicals Corporation Ltd Case Study, (Energy Manager Training)

A case study illustrating the successful implementation of energy efficiency measures within the polymer

industry.

http://www.energymanagertraining.com/new_best_practices_main.php

• Variable Speed Drives Save Energy and Costs in the Plastics Industry, (Department of Science

Technology and the Environment (DOSTE), Vietnam, 2002)

A case study illustrating how variable speed drives can help reduce energy consumption.

http://www.serd.ait.ac.th/reric/Variable%20Speed%20Drives%20-%20TFS%202%5B1%5D.pdf

Organisations

• Asia Pacific Economic Cooperation

Website www.apec.org

• Bangladesh Plastic Goods Manufacturers and Exporters

Website www.bangladeshplastic.org

• Bureau of Energy Efficiency, India

Website www.bee-india.nic.in

• China Plastics Processing Industry Association

Website www.cppia.com.cn

• Energy Manager Training, Indo German Energy Programme

Website www.energymanagertraining.com

• Indian NGOs.com

Website www.indianngos.com

• Indian Plastics Institute

Website www.inplasin.org

• Japan Centre for Climate Change Actions

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Website www.jccca.org

• Japan Environment Association

Website www.jeas.or.jp

• Japan Environment Management Association for Industry

Website www.jemai.or.jp

• Malaysian Plastics Manufacturers Association

Website www.mpma.org.my

• Ministry for Environment, Japan

Website www.env.go.jp

• Shanghai Energy Conservation Supervision Centre

Website www.cn-greenlights.gov.cn

• Singapore Plastic Industry Association

Website www.spia.org.sg

• The Federation of Thai Industries – Plastic Industry Club

Website www.ftiplastic.com

• The Indonesian Olefin and Plastic Industry Association

Website www.inaplas.net

• Vietnam Saigon Plastics Association

Website www.vnplas.com

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CANADA

Overview

There are many Canadian organisations playing a dynamic role in helping Canadians save millions of dollars in

energy costs while addressing the challenges of climate change. All of the organisations provide users of their

website a comprehensive publications and downloads section providing information on everything you need to

save energy, save money and help protect the environment while reducing greenhouse gas emissions that

contribute to climate change. They also illustrate, through the many programmes available for the residential,

commercial, industrial and transportation sectors, up-to-date information on energy efficiency, alternative energy

and clean fuels.

Established in 1998 as part of Natural Resources Canada, the Office of Energy Efficiency’s (OEE) mandate is to

renew, strengthen and expand Canada’s commitment to energy efficiency. The OEE began with Canada’s

commitment to reduce greenhouse gas emissions by 6% below 1990 levels by the period between 2008 and 2012,

as agreed in the Kyoto Protocol. Similarly, the Canadian Industry Program for Energy Conservation (CIPEC) is a

unique partnership between industry and government that works to improve the energy efficiency of each of

Canada’s industrial sectors. Other organisations include the Environment and Plastics Industry Council and

Ontario Power Authority.


• Energy Ideas, (Natural Resources Canada, 2004)

This is the annual report from the Canadian Industry Program for Energy Conservation (CIPCE). It

provides an overview of the energy management accomplishments of the participating sectors and

organisations.

http://oee.nrcan.gc.ca/publications/infosource/home/index.cfm?act=category&PrintView=N&Text=N

• Energy Management Information Systems, (Natural Resources Canada, 2003)

A handbook, designed for all levels of management and operational staff, providing a structured and

practical understanding of an Energy Management Information System.


• Saving Money through Energy Efficiency, (Natural Resources Canada, 2004)

This guide provides a step-by-step approach to designing and implementing an effective energy efficiency

awareness programme.


Organisations

• Advanced Design and Manufacturing Institute (ADMI)

Website http://www.admicanada.com

• Canadian Industry Program for Energy Conservation (CIPEC)

Website http://oee.nrcan.gc.ca/industrial/

• Environment and Plastics Industry Council

Website www.cpia.ca

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• Materials and Manufacturing Ontario

Website www.mmo.on.ca

• Ontario Power Authority

Website www.powerauthority.on.ca

• The Office of Energy Efficiency

Website http://oee.nrcan.gc.ca/english/index.cfm?attr=0

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DENMARK

Overview

Denmark promotes energy efficiency, renewables and combined heat and power production (CHP). It has set itself

several targets including producing 20% of its electricity from renewables and reducing greenhouse gas emissions

by 21% in the first budget period 2008-2012 compared to 1990. There is also a stringent national commitment to

reduce CO2 emissions by 20% by 2005, compared to 1988.


• Rationel Energianvendelse i Plastindustrien (Dansk Industri, Energi Radgivning Fyn,

Plastindustrien, 1998)

A guide demonstrating the rational energy usage in the plastic industry

• Demonstrationsprojekter (Dansk Industri, Energistyrelsen, 2002)

Demonstration projects

Organisations

• Aarhus Save Agency

Website www.veo.dk

• Association of Energy and Environment (SEK)

Website www.sek.dk

• Danish Energy Authority

Website www.ens.dk

• Danish Plastics Federation

Website www.plast.dk

• Energy Centre Denmark

Website www.ecd.dk

• Green City Denmark A/S

Website www.greencity.dk

• The Danish Organisation for Renewable Energy

Website www.orgve.dk

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GERMANY

Overview

There are no best practice guides or publications, specific to energy efficiency and plastics processing, available in

Germany. However, there is information available regarding environmental protection as a result of national and

feasibility studies, (Example: Gosner 2000).


• A part government funded project in the Nordrhein-Westfahlen region produced a booklet entitled ‘Energy

Saving Concepts in Industrial Branches’, illustrates energy saving possibilities in plastics engineering,

(Trautmann et al 2002). It provides an overview of energy saving strategies in the different polymer

processing techniques.

• The Bavarian Environmental Protection Agency published a guide focusing on CO2 decreasing potential in

the plastics processing industry, (BayLfU, 2002).

• The University for Applied Science, Ansbach, Germany carried out a feasibility study on small and medium

enterprises (Kirchhöfer, 2001).

• Haag (2005) provide further details regarding injection moulding and material management using software

simulation tools.

References

Gosner 2000 Gosner, Jürgen

Umweltschutz in der Kunststoffverarbeitung – Kunststoffverarbeitung, Broschüre der

Senatsverwaltung für Stadtentwicklung, Vorhaben 20594/1 UFP V, ARGUS e.V., Berlin

Kirchhöfer 2001 Kirchhöfer, Hermann

CO2-Einsparung durch rationelles Energiemanagement in klein- und mittelständischen

Unternehmen der kunststoffverarbeitenden Industrie Mittelfrankens, Pilotstudie,

Fachhochschule Ansbach, 2001

Trautmann 2002 Trautmann, Andreas; Meyer, Jörg; Herpetz Stefan;

Rationelle Energienutzung in der Kunststoff verarbeitenden Industrie, Vieweg Verlag,

Braunschweig/Wiesbaden 2002, ISBN 3-528-05810-2

BayLfU 2002 Bayrisches Landesamt für Umweltschutz

CO2-Minderungspotenziale durch rationelle Energienutzung in de

Kunststoffverarbeitenden Industrie, Augsburg 2002

Haag 2005 Haag, Günter; Binder, Jan; Liedl, Philipp

Rationelle Energieeinsparung und Minimierung des Materialeinsatzes beim Spritzgießen

(REMIS) – Teilvorhaben: Modellierung und statistische Analyse, Steinbeis-

Transferzentrum Angewandte Systemanalyse, Stuttgart 2005

Trade publications also provide technical proceedings with a focus on processing techniques including the energy

saving aspects.

- 13 -

Articles relating to energy saving in plastic processing – Kunststoffe Magazine

• Wortberg, Johannes; Kamps, Thomas; Schiffers, Reinhard: Energieaufnahme:

Welche Energie kostet ein Antrieb?

Erschienen in Kunststoffe 03/2003, Seiten: 64-70

• Wortberg, Johannes; Schroer, Thorsten:

Materialversorgung: Mehr Effizienz beim Trocknen


• Kleinebrahm, Michael:

Nur die Wirtschaftlichkeit zählt

Antriebskonzepte für Spritzgießmaschinen


• Liebig, Gerd:

Nur der Nutzen zählt

Leistungsvergleich zweier hybrider und vollelektrischer Maschinen


• Kraibühler, Herbert:

Modulare Antriebssysteme im Fokus

Arburgs Technologie-Tage mit neuen Technik-Highlights


• Henkel, Isabelle; Becker, Jens:

Energie-Contracting: Energieeffizienz senkt Betriebskosten


• Thielen, Michael:

Blasformen: Mehr als nur heiße Luft


• Wortberg, Johannes; Kamps, Thomas:

Kosten und Leistung: Antriebstechnik im Vergleich


• Wortberg, Johannes; Kamps, Thomas; Schiffers, Reinhard:

Antriebstechnik im Vergleich

Spritzgießmaschinen mit unterschiedlichen Antriebsarten im Praxisvergleich


• Fischer, Jürgen:

Schäumbares Polystrol (EPS)

- 14 -


• Hörl, Thomas; Betsche, Markus:

Modularität: Multitalent für wirtschaftliche Spritzgießfertigung


• Michaeli, Walter; Bölinger, Simone; Kudlik, Nikolaus:

Die richtige Maschine, aber welche?

Ein Kennzahlensystem hilft bei der Spritzgießmaschinenauswahl


• Liebig, Gerd; Mehler, Christoph:

Kostenbewusstsein: Moderne Technologie ist wirtschaftlicher als Low-spec


• Thielen, Michael:

Blasformen: Formen mit Luft


• Kotzab, Werner:

Der Impuls zum Energie sparen

Ein neues System zur Werkzeugtemperierung


• Schneider, Hans-Peter:

Wirtschaftlichkeit und Qualität gesteigert

Trends in der PVC-Profil- und Rohrextrusion


Articles relating to energy saving in plastic processing – FIZ Technik

• Michaeli, W.; Schmitz, T.

Lohnender Vergleich. Extrusion von PET-Folien mit Entgasung, Inst f Kunststoffverarb (IKV), RWTH

Aachen, DE, Zeitschriftenaufsatz: Plastverarbeiter / 2004 / 200410 03977

• Lewan, M.; Campion, R.; Iddon, M.

Of the NFM Iddon cold feed extruder and novel low temperature curing EPDM to reduce processing and

curing energy consumption, Konferenz-Einzelbericht: Engineering Elastomers, 1 / 2003 / 200404 02611

• Kuhn, G.; Jacoby, T.

Technische Möglichkeiten zur Dampfeinsparung in der EPS-Formteilherstellung. Erlenbach, Lautert, DE

Technological possibilities for saving steam in the EPS moulding. Konferenz-Einzelbericht: Schriftenreihe

Kunststofftechnik (VDI) / 2003 / 200401 05839

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• Hoffmanns, W.

Kühle Behandlung. Kälteanlagen für den kunststoffverarbeitenden Betrieb, Zeitschriftenaufsatz:

Plastverarbeiter / 2003 / 200307 09039

• Zlotos, M.

Trocknen mit Trockenluft: Wirtschaftlich und energiesparend. Technische und betriebswirtschaftliche

Betrachtung der Trockenlufttrocknung, Mann+Hummel ProTec, Ludwigsburg, DE, Zeitschriftenaufsatz:

Kunststoffberater / 2002 / 200209 05847

• Miethlinger, J.; Mayr, A.

Teppiche beschichten. Geringerer Energieverbrauch und bessere Rezyklierbarkeit SML Maschinenges,

Lenzing, AT, Zeitschriftenaufsatz: Kunststoffe, München / 2001 / 200105 00683

• Neubert,T.; Helbig A.; Helduser S.

Regelbare Pumpenantriebe verbessern Spritzgießmaschinen TU Dresden, DE, Zeitschriftenaufsatz: MM -

Maschinenmarkt, Würzburg / 2000 / 200011 05614

• Kleinebrahm, M;

Nur die Wirtschaftlichkeit zählt. Antriebskonzepte für Spritzgießmaschinen, Boy, Neustadt/Wied, DE

Zeitschriftenaufsatz: Kunststoffe, München / 1999 / 200001 01143

• Schreiber, M.; Meyer, J.; Starke, M.; Haug, M.; Wittmer, A.

Verringerung des Wärmeenergieeinsatzes in einem Unternehmen der kunststoffverarbeitenden Industrie

mittels dynamischer Simulation unter besonderer Berücksichtigung produktionstechnischer Belange,

Konferenz-Einzelbericht: VDI-Berichte / 1999 / M9907 1041 561

• Hoffmanns, W.

Luftgetrocknet. Trockner für Schüttgüter in der Kunststoffverarbeitung. Blick in den Markt

Zeitschriftenaufsatz: Plastverarbeiter / 1999 / M9905 1560 603

• Wortberg, J.; Michels, R.; Neumann, M.

Kunststoffverarbeitung bietet Potential für deutliche Energieeinsparung, Univ -GH Essen,

DE,Zeitschriftenaufsatz: Maschinenmarkt, Würzburg / 1999 / M9902 1216 533 Wortberg-J; Michels-R;

Neumann-M / Univ -GH Essen, DE

• Elektromechanisch angetriebene Blasformmaschinen - Eine Vision?

Konferenz-Einzelbericht: Kunststofftechnik / 1997 / M9710 0253 563

• Zeppenfeld, R.;

Energiemanagement. Kosten senken im Spritzgießbetrieb; Ges Wärme Kältetech, Kierspe, DE,

Zeitschriftenaufsatz: Kunststoffe, München / 1997 / M9702 0720 603

- 16 -

NEW ZEALAND

Overview

In March 2005, the New Zealand Cabinet confirmed a policy to assist energy-intensive businesses (EIBs) to reduce

greenhouse gas emissions and to alleviate the possible adverse effects of the new carbon tax (to be introduced in

2007) through improved energy efficiency. A pilot scheme was introduced in 2005 to test the effectiveness of the

grant scheme and demonstration projects, which included the plastics industry.

The Energy Efficiency and Conservation Authority and the Climate Change Group in the Ministry for the

Environment, in consultation with industry associations, select technologies that are capable of delivering

significant energy savings. These technologies are then demonstrated in the pilot scheme and the case studies

disseminated through the EECA website and trade associations.


• National Energy Efficiency and Conservation Strategy, (Ministry for the Environment, 2001)

The purpose of the strategy is to promote energy efficiency, energy conservation and renewable energy

within the context of a sustainable energy future.

http://www.eeca.govt.nz/pdfs/national_energy_efficiency_and_conservation_strategy.pdf

• Reducing Motor Drive Energy Costs, (Energy Efficiency and Conservation Authority, 2003)

A technical guide detailing how to reduce motor drive energy costs

http://www.eeca.govt.nz/uploadedDocuments/Reducing%20motor%20drive%20energy%20costs.pdf

• The Plastics Sustainability Initiative, (Plastics New Zealand, 2004)

The New Zealand Plastics Sustainability Initiative is a five-year agenda for action launched in 2003 to

minimise the effect of the industry and its products on the environment.

http://www.plastics.org.nz/_attachments/docs/sustainability.pdf

• Energy Case Studies, (Business Care New Zealand)

Case studies illustrating how to use resources such as water, energy and raw materials efficiently.

http://www.businesscare.org.nz/casestudies/subject.asp

Organisations

• Business Care

Website www.businesscare.org.nz

• Energy Efficiency and Conservation Authority (EECA)

Website www.eeca.govt.nz

• Energy Information New Zealand

Website www.energyinfonz.com

• Energy Library and Information Services

Website www.energylibrary.co.nz

• Energy Management Association of New Zealand

Website www.ema.org.nz

• New Zealand Climate Change Office

- 17 -

Website www.climatechange.govt.nz

• Plastics New Zealand

Website www.plastics.org.nz

- 18 -

SPAIN

Overview

There are several organisations within Spain promoting the efficient use of energy in the country. For example, the

Institute for Energy Diversification and Saving (IDAE) promotes energy efficiency and the rational use of energy,

supports the diversification of sources of supply and promotes the use of renewable sources of energy. The

Institute carries out dissemination, awareness-raising and advisory services for all energy consuming sectors.


• Plan de Ahorro y Eficiencia Energética de la Cominidad Valenciana, Sector Industrial, Peridodo

2001-2010, AVEN. Generalitat Valenciana

Energy Saving and Efficiency Programme in the Valencian Community (Spain), Industrial Sector, Period

2001-2010. Valencian Energy Agency (AVEN), Generalitat Valenciana (Regional Government)

• Plan de Ahorro y Eficiencia Energética en Andalucía, 2004-2006, Junta de Andalucía, Industria del

Plastico

Energy Saving and Efficiency Programme in Andalucía (Southern Spain), Period 2004-2006, Plastic

Industry

• Focus, Environmental Energy Efficiency Guide for Businesses, (Departamento de Medio Ambiente

del Reino Unido, IHOBE S.A., CADEM, 2001)

This publication analyses the use of energy in companies displaying several measures aiming to save

money. Sections included are: lighting, heating, water, boilers, electrical equipment, compressed air,

vehicles, fuel purchase and business management.

http://www.ihobe.es/pags/AP/Ap_publicaciones/index.asp?cod=279

• Energy & Environment in the Basque Autonomous Community, (IHOBE, 2003)

Following the introduction of the Basque Environmental Strategy for Sustainable Development 2002-2020,

this is the first document on energy and environment indicators in the Basque Autonomous Community.

http://www.ihobe.es/pags/AP/Ap_publicaciones/index.asp?cod=279

Organisations

• Agencia Valenciana de la Energía (AVEN)

Website www.aven.es

• IHOBE

Website www.ihobe.es

• Institute for Energy Diversification and Saving (IDAE)

Website www.idae.es

- 19 -

UNITED KINGDOM

Overview

UK plastics companies are facing average price increases of 56% for electricity and 58% for gas according to a

new 2005 survey carried out by the British Plastics Federation (BPF). Furthermore, national energy consultancy,

Energy 2000, have warned that businesses should expect up to a staggering 60% increase in their overheads as a

result of a ripple-effect on the supply chain, from this year’s energy price rises alone, (Source: Manufacturing Talk).

There are many organisations promoting energy efficiency in industry, and specifically the plastics industry. For

example, the Carbon Trust is an independent company funded by the Government to help the UK move to a low

carbon economy. Their aim is to help businesses and the public sector reduce carbon emissions now and capture

the commercial opportunities of low carbon technologies. A second organisation, Envirowise, is a Government

programme offering free, independent and practical advice to UK businesses to reduce waste at source and

increase profits. They both (as well as many other organisations) provide best practice guidelines and case studies

through their website on how different sectors (including plastics) can reduce their energy consumption.


• Energy Efficient Thermoplastics Extrusion, (Department of the Environment, Transport and the

Regions, 1998)

A Good Practice Guide (239) providing advice on practical ways of improving energy efficiency in the

extrusion of thermoplastics.

http://www.thecarbontrust.co.uk/energy/pages/publication_search.asp?PubID=3508&PubPath=%5CIndustr

y%2Fbusiness+area%5CRubber+%26+Plastics#

• Energy in Plastics Processing – A Practical Guide, (ETSU, 1999)

A Good Practice Guide (292) to assist owners and operators of plastics manufacturing facilities to save

energy and improve the cost effectiveness of their operations.

http://www.thecarbontrust.co.uk/energy/pages/publication_search.asp?PubID=3508&PubPath=%5CIndustr

y%2Fbusiness+area%5CRubber+%26+Plastics#

• Energy Efficiency Training and Development, (Department of the Environment, Transport and the

Regions, 1998)

A Good Practice Guide (85) explaining why energy management training is important for both individuals

and organisations and outlines the help available for those seeking energy efficiency training.

http://www.actionenergy.org.uk

• Energy Efficient Tooling for Injection Moulding, (Carbon Trust, 2004)

A fact sheet illustrating the project, to develop injection moulding tooling which will reduce the specific

energy required in injection moulding.

http://www.thecarbontrust.co.uk/carbontrust/low_carbon_tech/projects/2002-2-35%20Leeds.pdf

• Managing and Motivating Staff to Save Energy, (Department of the Environment, Transport and the

Regions, 1993)

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A Good Practice Guide (84) to show the important part that people play in managing energy. It

emphasises that energy is a management issue and offers guidance on how to start an energy saving

campaign, with particular advice on how to motivate staff to save energy.

http://www.thecarbontrust.co.uk/energy/pages/publication_search.asp?PubID=3523&PubPath=%5CPublic

ation+type%5CGood+Practice+Guides#

• Resource Efficiency, (Enworks)

A business guide to making environmental practice profitable.

http://www.enworks.com

• The Business Energy Efficiency Programme

A guide illustrating why being energy efficient is good for a business. A detailed case study is also

provided.

http://www.britishgasbusiness.co.uk

• 6-step Energy Saving Plan, (ABB Ltd, 2003)

A guide to the 6 step plan to energy saving, including energy appraisals, management, savings, energy

efficient products and how to make an impact on your energy bill.

http://www.abb.co.uk/energy

• Climate Change and your Business, (The Carbon Trust, 2004)

An information pack providing advice on saving energy quickly and easily at little or no cost.

http://www.thecarbontrust.co.uk/energy/pages/page_30.asp

• Energy and Environment SME Toolkit, (Federation of Small Businesses in Scotland, Scottish

Executive, 2003)

A guide on how to cut waste, energy, water and transport and comply with environmental legislation. The

toolkit is designed to help you cut your business running costs, and ensure you operate within all the

regulations that may apply to you.

http://www.energy-efficiency.org/pdf/toolkit.pdf

• Energy Efficiency, (EEBPP, 2001)

The first in a series of energy efficiency worksheets to assist the plastics industry reduce costs through the

efficient use of energy.

http://www.pcn.org/Technical%20Notes%20-%20Energy%20(1%20-%208).pdf

• Energy Management at a large Injection Moulding Site, (ETSU, 2000)

A Good Practice Case Study (225) demonstrating the energy savings that can be achieved by introducing

basic energy management techniques to a large plastics injection moulding site.

http://www.thecarbontrust.co.uk/energy/pages/publication_search.asp?PubID=3508&PubPath=%5CRubbe

r+%26+Plastics

• An Introductory Guide to Energy Performance Assessment, (The Carbon Trust, 2005)

The guide aims to clarify some of the common problems that are encountered when using specific energy

consumption (SEC) as a performance indicator and presents a simple approach to assessing energy

performance that allows meaningful comparisons.

http://www.thecarbontrust.co.uk

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• Reducing Electricity use in Extrusion – Blow Moulding of Thermoplastic, (Department of the

Environment, Transport and the Regions, 1994)

A Good Practice Guide (92) aimed at businesses wanting to reduce the electricity costs incurred in

extrusion-blow moulding. The guide describes the ways in which electrical energy is used to make

extrusion-blow mouldings of thermoplastics. It shows how much energy is used by a wide variety of

companies, suggests where energy savings may be looked for during the process and describes how

energy may be managed and saved.


ation+type%5CGood+Practice+Guides

• Organisation Aspects of Energy Management – A Self Assessment Manual for Managers, (BRECSU,

1995)

This guide has been designed to help managers bring about improvements in how their organisations

manage energy consumption.


ation+type%5CGood+Practice+Guides

• Reducing Electricity Use in Injection Moulding, (Department of the Environment, Transport and the

Regions, 1998)

A Good Practice Guide (48) describing the ways in which energy is used to make injection mouldings. It

shows how much energy is used by a variety of moulding companies, suggests where any savings may be

looked for during the process and describes how much energy may be saved and managed.

http://www.thecarbontrust.co.uk

• Energy Efficiency in Plastics Processing – Technical Update 1 – All Electric Injection Moulding

Machines, (Carbon Trust & Polymer Machinery Manufacturers and Distributors Association)

A guide illustrating the benefits of electric injection moulding machines.

http://www.pmmda.org.uk/TU1%20-%20All-electric.PDF

• Resource Efficiency: Cut costs in plastics processing, (Envirowise, 2003)

This Envirowise Good Practice Guide provides training materials to help plastics processing companies

implement a resource efficiency programme.

http://www.envirowise.gov.uk

Organisations

• ABB Ltd

Website www.abb.co.uk/energy

• British Gas Business

Website www.britishgasbusiness.co.uk

• British Plastics Federation

Website www.bpf.co.uk

• Envirowise

Website www.envirowise.gov.uk

• Enworks

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Website www.enworks.com

• Polymer Machinery Manufactures & Distributors Association (PMMDA)

Website www.pmmda.org.uk

• Tangram Technology Ltd

Website www.tangram.co.uk

• The Carbon Trust

Website www.thecarbontrust.co.uk

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UNITED STATES

Overview

The plastics industry consumes approximately 6% of all the energy used by U.S. industries, and is valued at $6

billion (based on 1998 DOE and other data). The DOE estimates that reducing the plastics industry’s energy use

by as little as 1% by 2010 may reduce the total annual energy costs by $100 million. In 2003, the Society of the

Plastics Industry Inc. and DOE formed a partnership to identify the potential for plastics manufacturers to reduce

their overall energy use, enhance productivity and save money.

Further US organisations promote and analyse technologies, process innovations and policies to increase the

energy efficiency and competitiveness of manufacturing industries.


• Efficiency and Innovation in US Manufacturing Energy Use, (National Association of Manufacturers,

2005)

A booklet aimed at manufacturers who want to achieve more strategic control over rising energy costs.

http://www.nam.org/s_nam/sec.asp?CID=216&DID=214

• Energy Accounting: A key tool in managing energy costs, (California Energy Commission, 2000)

A guide explaining energy accounting, including background information, how to get started and the use of

software packages.

http://www.energy.ca.gov/reports/efficiency_handbooks/

• Energy Tips #1 – Compressed Air, (US Department of Energy, Energy Efficiency and Renewable

Energy, 2004)

Fact sheet about how to determine the cost of compressed air.

http://www.eere.energy.gov/industry/bestpractices/pdfs/compressed_air.pdf

• Energy Tips #4 – Compressed Air, (US Department of Energy, Energy Efficiency and Renewable

Energy, 2004)

Fact sheet about how to determine your compressed air requirements

http://www.nrel.gov/docs/fy04osti/36140.pdf

• Industrial Energy Management in Action, (Office of Energy Efficiency and Renewable Energy, 2001)

Examples of manufacturers that have applied energy and process efficient technologies, cut costs,

increased productivity and improved overall competitiveness.

http://www.eere.energy.gov/industry/bestpractices/pdfs/plantprofiles.pdf

• Selling an Energy Project to Management, (US Department of Energy, Energy Efficiency and

Renewable Energy, 2000)

Guide on how to get management buy in for energy projects.

http://www.eere.energy.gov/industry/bestpractices/jul2000_guest.html

• Improving Energy Efficiency at US Plastics Manufacturing Plants, (The Society of Plastics

Industries Inc. and US Department of Energy, 2005)

A summary report and case studies identifying the potential for plastics manufacturers to reduce their

overall energy use, enhance productivity and save money.

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http://www.eere.energy.gov/industry/bestpractices/pdfs/plastics_report.pdf

• Plastics Industrial Assessment, (US Department of Energy, Energy Efficiency and Renewable

Energy, 2003)

A case study illustrating how the Bemis Manufacturing Company, a compression moulding company,

saved more than $22,000 per year by implementing the Industrial energy assessment recommendations.

• Reducing Energy Costs in Plastics Injection Moulding, (Centre for Energy Efficiency and

Renewable Energy, University of Massachusetts, 2004)

A PowerPoint presentation demonstrating how the Industrial Assessment Centre assisted plastic injection

moulders to reduce their energy costs.

http://www.maeep.org/documents/kosanovic%20-%20Pittsfield%20Oct%202004.ppt

Organisations

• American Council for an Energy Efficient Economy

Website www.aceee.org

• California Energy Association

Website www.energy.ca.gov

• National Associations of Manufacturers

Website www.nam.org

• Plastic Institute of America

Website www.plasticsinstitute.org

• Society of Plastics Engineers

Website www.4spe.org

• US Department of Energy, Energy Efficiency and Renewable Energy

Website www.eere.energy.gov

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ADDITIONAL INFORMATION

A search was carried out in the following countries for best practice guidelines however there were none readily

available. Nevertheless, the following organisations were identified as having significance for the plastics industry.

ARGENTINA

• Plastivida Argentina

Website www.plastivida.com.ar

AUSTRALIA

• Plastics and Chemical Industries Association

Website www.pacia.org.au

BELGIUM

• Agoria Plastics

Website www.agoria.be

• Association of Belgian Manufactures of Reinforced Plastics/Composites

Website www.agoria.be/agoriaplast/en/reinforplast.htm

• Association of Plastics and Rubber Converters (Febelplast)

Website www.fedichem.be

• Federation of Enterprises in Belgium

Website www.vbo-feb.be

• Flemish Plastics Technology Centre

Website www.vkc.be

• Plastics and Rubber Manufacturers and Trading Companies (Fedichem Polymers)

Website www.fedichem.be

BRAZIL

• Plastivida Brazil

Website www.plastivida.org.br

CHILE

• Chilean Plastics Industries Association

Website www.asipla.cl

FRANCE

• Syndicat des Producteurs de Matiéres Plastiques (SPMP)

Website http://spmp.sgbd.com

• Federation de la Plasturgie

Website www.laplasturgie.fr

• Association Française des Industries de Moule, Modèle et Maquette

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Website www.afim-france.com

• Société Française des Ingénieurs des Plastiques (SFIP)

Website www.sfip-plastic.org

ITALY

• Italian Association of Plastics Recyclers (ASSORIMAP)

Website www.assorimap.it

• Italian Plastics and Rubber Processing Machinery and Moulds Manufacturers Association

(ASSOCOMAPLAST)

Website www.assocomaplast.org

• MACPLAS

Website www.macplas.it

• National Association of Plastics Manufacturers (PLASTICSEUROPE ITALIA)

Website www.plastica.it

• Rubber and Plastics Federation

Website www.federazionegommaplastica.it

• UNIONPLAST

Website www.unionplast.it

SOUTH AFRICA

• Plastics Federation of South Africa

Website www.plasticsinfo.co.sa

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CONCLUSIONS

Countries Surveyed

A total of 25 countries were surveyed from inside and outside of the EU to identify information related to best

practice guidance and energy efficiency in the plastics processing industry. Of the countries surveyed only 9 have

national guidelines readily available, however, within the remaining countries there are trade and specialist

organisations for the plastic and energy industries.

Guidelines Available

In total 42 documents were sourced covering energy efficiency in the plastics industry and general manufacturing.

Table 1 – Breakdown of available energy efficiency guidelines

Best practice guidelines specifically for the plastics industry 40%

Case studies specifically aimed at the plastics industry 7%

General case studies relating to energy efficiency in industry 5%

General best practice guidelines relating to energy efficiency in industry 31%

Energy strategies 10%

Technical guides 7%

This survey has generated enough information to understand what constitutes best practice for the industry. It also

provides insights into the attitudes and policies of each of the surveyed countries.

Next Steps

Growth in the European plastics industry is either relatively static or declining as processors face intense

competition from lower wage economies as well as increases in the price of energy. RECIPE aims to provide

plastics processors with the knowledge, justification and tools needed to reduce energy consumption through the

implementation of best practice and the introduction of new technologies. Therefore, the next steps will be: -

1. An industry specific guide promoting the best of the best. The European Best Practice Guide for the

plastics processing industry will provide advice related to the processes and working practices. The guide

will cover the major processes as well as details on how to get the buy-in of management, encourage and

motivate staff to reduce/save energy, purchasing energy and monitoring consumption. This will be

available from February 2006.

2. A series of fact sheets will be produced addressing specific design issues related to energy consumption in

plastics injection moulding, including the use of software packages, design of pumps and heat exchangers

and advances in cooling.

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REDUCED ENERGY CONSUMPTION IN PLASTICS ENGINEERING

REVIEW OF ENERGY MANAGEMENT PRACTICES, BEST PRACTICE &

TRENDS WITHIN THE PLASTICS PROCESSING INDUSTRY ACROSS THE

WORLD

APPENDIX 1 – COUNTRIES SURVEYED

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APPENDIX 1

Countries Surveyed

1. Argentina

2. Australia

3. Bangladesh

4. Belgium

5. Brazil

6. Canada

7. Chile

8. China

9. Denmark

10. Germany

11. France

12. India

13. Indonesia

14. Italy

15. Japan

16. Malaysia

17. New Zealand

18. Singapore

19. South Africa

20. Spain

21. Thailand

22. Turkey

23. United Kingdom

24. United States

25. Vietnam

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